Electromagnetic switch



Oct. 16, 1962 J. H. HORMAN 3,059,076

ELECTROMAGNETIC SWITCH Filed April 5, 1960 s' sheets-sheet `1 MJT INVENTOR. JOHN H. HORMAN BY-fym.'

ATTORNEY Oct. 16, 1962 J. H. HoRMAN 3,059,076

ELECTROMAGNETIC SWITCH Filed Apil 5, 1960 s sheets-sheet 2 4e 63 p 4s n A 45e; I i

INVENTOR.

JOHN H HORMAN ATTORNEY OCt- 16, 1952 J. H. HORMAN 3,059,076

ELECTROMAGNETIC SWITCH Filed April 5. '1960 s sheets-sheet s FIG.8

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'4 JOHN H .HORMAN VMM/M,

ATTORNEY United States Patent 3,059,076 Patented Oct. 16, 1962 ice 3,059,076 ELECTROMAGNETIC SWITCH John H. Horman, Yonkers, N.Y., assigner to Allied Control Company, Inc., New York, N.Y., a corporation of New York Filed Apr. 5, 1960, Ser. No. 20,192 12 Claims. (Cl. 200 98) This invention relates to the art of electric switch apparatus and, more particularly, to an electromagnetic switch or relay having improved features of design and construction. The invention pertains, in one of its more specific aspects, to a small size relay including a pair of rotary armatures that are adapted to be operated simultaneously and in unison.

This is a continuation-in-part application of my pending application Serial No. 1,057, iiled January 7, 1960, and entitled Electromagnetic Switc now Patent No. 3,040,145.

The relay of this invention has many and varied applications. It is especially useful in environments, such as on aircraft, which may be subjected to high inertia forces due to shock, vibrations and sudden acceleration or deceleration and in which space for operating equipment is limited.

As is stated in my said pending application, there has been considerable activity in recent years in the field of relays employing rotary armatures. Such activity is eX- emplied by my Patent No. 2,777,922, dated January 15, 1957, for Electromagnetic Switch, and J. S. Zimmer Patent No. 2,824,189, dated February 18, 1958, for Electromagnetic Switching Device. Both of these patents disclose electromagnetic relays which utilize a single rotary armature for actuating movable contact members. My present invention constitutes a novel and useful improvement over the relays of these patents as will be evident from the detailed description that follows.

One of the important features of the relay of this invention is that it is extremely compact and lends itself to better stacking in panel assemblies than conventional relays of equivalent capacity. For example, a six pole double throw relay embodying this invention may be made in a size that is only slightly larger than a presently available relay having a single rotary armature and capable of controlling only one third as many circuits.

Another important feature of the subject relay is that, by virtue of the configuration and relative position of its rotary armatures and other parts, the relay effectively withstands shock forces, vibrations and the like in normal use. Accordingly, only a light duty holding spring is needed for each or both armatures, depending on the construction, and a relatively small electrical force is required to simultaneously actuate both armatures against the action of the spring and operate corresponding movable contacts.

The relay of this invention affords a number of advantages which make it particularly useful in printed panel work which requires eflicient use of space. Among such advantages are the following:

( 1) It is extremely compact;

(2) Its overall height is small as compared to conventional relays of equivalent capacity;

(3) All terminals of a multi-pole relay, such as the six pole double throw relay which is described further along herein, are carried by a single header plate and are conveniently accessible for making necessary connections; and

(4) All contacts of the relay are arranged in one plane,

parallel and close to the header plate to keep the resistance, inductance and capacitance of each contact circuit substantially equal and at a minimum.

The primary object of this invention is to provide a compact electric relay that is capable of being made in small or miniature size and that is adapted to withstand shock forces, vibrations and sudden acceleration or deceleration in the course of normal use.

Another object of the invention is the provision of a relay of improved design and construction, including a pair of rotary armatures which operate in unison to thereby actuate corresponding independent movable contact members substantially simultaneously.

A further object of the invention is to provide a compact multi-pole relay, such as a six pole double throw relay, wherein all contacts are arranged in a common plane and all terminals are carried by a single header plate and are conveniently accessible for making necessary connections.

A still further `object of the invention is to provide a relay of the character indicated that is small and lightweight in design, that is sturdy and durable in construction, that is reasonable in manufacturing cost and that is capable of performing its intended functions in a satisfactory .and reliable manner.

The foregoing objects and additional objects, together with the advantages of this invention, will be apparent to persons trained in the art from the following detailed description and the accompanying drawings which describe and illustrate, by way of example, a six pole double throw relay embodying the invention.

In the drawings, wherein like reference characters denote corresponding parts throughout the several views:

FIG. l is a top plan view of a relay constructed in accordance with the invention;

FIG. 2 is an isometric view of a frame Which is part of the relay of FIG. 1;

FIG. 3 is a view in enlargement taken along line 3 3 of FIG. l;

FIG. 4 is a view taken along line 4 4 of FIG. 3;

FIG. 5 is a view taken along line 5 5 of FIG. 3 g

FIG. 6 is a View taken along line 6 6 of FIG. 5, the casing being omitted for better illustration or other parts;

FIG. 7 is ,a View taken along line 7 7 of FIG. 6, certain parts being shown in cross-section and other parts broken away for better illustration of still other parts;

FIG. 8 is a view taken along staggered line 8 8 of FIG. 3;

FIG. 9 is a view taken along line 9 9' of FIG. 3;

FIG. l0 is an enlarged view in front elevation of one of the armatures of the relay;

FIG. ll is a side elevation view of the armature shown in FIG. l0;

FIG. 12 is a bottom lan view in FIG' 10; p of the armature shown FIG. 13 is an enlarged view in elevation of a bearing plaltncrmature shaft assembly; and

is a view taken alon sta FIG' 13. g ggered line 14 14 of Referring initially to FIGS. 1 and 3 of the drawings, I have illustrated therein a one-piece tubular casing or housing K15 which is open at its lower end and is closed at its upper end, as indicated at 16. Secured to opposite sides of the housing by soldering or biazing is a pair of brackets 17 having openings 18 `for receiving screws 0r the like whereby the casing may be attached to a support, such as a panelboard.

A one-piece frame F for supporting electromagnetic devices is positioned wholly within casing I15 and is best shown in FIG. 2. The frame is non-magnetic and includes a bottom wall 20 having transverse openings 21, a pair of upstanding parallel side walls 122 and a plurality of depending legs 23. Each leg terminates in a foot element 24. The upper marginal portion of each side wall is cut out and bent outwardly to obtain fingers 25 and 26, the latter being notched, as indicated at 27. Each finger 25 serves as a stop element to limit pivotal movement of a corresponding armature in one direction as will be described further along herein. Each linger 26 serves as an anchor for one end of a spring as will also be described. Each frame plate is formed with a pair of horizontally spaced openings 28 and a central opening 29 which is spaced from and located midway between openings 28. It will be observed that openings 23 and 29 of one side Wall are aligned with like openings in the other side wall.

.Frame F supports an electro-magnet unit 30 which includes a pair of spaced parallel bobbins 31 that are located between and bear against frame side walls 22 and a pair of magnetizing coils C, each of which is wound around a corresponding bobbin. The coils are sheathed in protective outer wrappers of a suitable insulating material. The coils are electrically connected and are provided with insulated leads 33 and 34 which extend through openings 21 in the frame bottom wall.

Each coil is provided with a rectilinear pole piece P which is made of a good magnetic material, such as soft iron or annealed steel. Each pole piece consists of a shank 35 and a head 36, both of which are right circular cylindrical. As is best shown in FIG. 8, the pole pieces extend through the frame side walls and corresponding bobbins. The free end of each pole piece shank 35 is equipped with a spacer sleeve 37 which is also right circular cylindrical and has the same size outer diameter as head 36. A narrow bearing plate 38 extends across and bears against the extremities of corresponding ends of the pole pieces. The pole pieces are axed to plates 38, preferably Iby soldering. -It will be appreciated from an examination of FIG. 8 that the illustrated arrangement of pole pieces P, sleeves 37 and plates 38 maintains the pole pieces in position relative to the coils and the frame side walls. An armature shaft 40 is afxed to each bearing plate 38 midway between the pole pieces through the medium of an extension 41 which projects through a central opening in the plate and is riveted over, as illustrated in FIG. 14. The armatures have a common axis which is located between coils C.

The electromagnet unit also comprises a pair of laminated armatures A which are best shown in FIGS. 10, ll and l2. Each armature includes a pair of oppositely curved balanced arms 42. These arms are disposed t opposite sides of a central through opening 43 in the armature. Shafts 40 extend through corresponding armature openings 43, the parts ybeing so constructed and arranged that the armatures are independently rotatable about the common axis of the shafts. Each armature arm `42 defines a semi-circular recess 44 having a diameter which is slightly larger than the outer diameters of pole piece heads 36 and sleeves 37. Each armature is provided with a plurality of contact actuators 45a, 45h and 45C, each consisting of a corresponding arm 46a, 46b, and 46c which are welded to a corresponding armature and to each other, as indicated at 47 in FIG. 10, and an insulating element, such as a glass bead 48, ywhich is formed at its free end.

A hook element 50 is welded to each armature as indicated at 51. Each armature is equipped with a light holding spring 52 which is connected at one end to a hook element 50 and at its other end to a frame finger 26, as best shown in FIG. 3. The parts are so constructed and arranged that each spring normally and yieldingly urges its armature in a direction .about the axis of shafts 40 so that armature arms 42 are biased away from the pole pieces to the extent allowed by stop ngers (FIG. 3).

Reference is next had to FIGS. 5, 6 and 7 which illustrate details of construction of a header assembly H that includes a support plate 53. This plate is positioned below and in spaced relation to the bottom wall of the frame and is provided with edge slots (not shown) for receiving corresponding feet 24 of the frame legs. These -feet are rigidly aflixed to the plate lby welds, as` indicated at 54. The support plate carries electrical connections, switch contacts and other elements that will now be identified and described. Such parts include a total of twenty lixed terminals consisting of six pairs of terminals 55 and 56, terminals 57 and 58, and six terminals 59. All terminals extend through plate 53 and are anchored to and insulated from the plate corresponding masses of a suitable, rigid, insulating material, such as glass 60. Aflixed to each terminal 55 and 56 is a corresponding L- shaped stationary contact 55a and 56a, respectively. Terminals 57 and 58 are respectively connected to coil leads 33 and 34 and are adapted to be connected to a suitable source of electric energy supply.

The support plate carries a total of six movable contacts in the form of electrically conductive leaf spring contact arms 61. Each contact arm is anchored at one end to a corresponding terminal 59 and is provided at its other end with a contact button l62. It will be observed from an examination of FIG. 6 that a contact button 62 is located between stationary contacts `55a and 56a of each pair of terminals 55 and 56. Each contact arm 61 normally biases its contact button 62 into engagement with the corresponding stationary contact 55a. The contact arms are all arranged for flexing movement along corresponding paths which are all located in a common plane. This plane is substantially parallel to the axis of the armature shafts and a plane which is common to the armature shafts and the axes of the pole pieces. The free ends of the contact arms are provided with integral upwardly projecting extensions 63. Each extension 63 extends across the path of movement of a corresponding actuator bead `48 and is adapted to be llexed by that bead, in response to operation of its armature A, to effect disengagement of its contact button `62 lfrom its stationary contact 55a and effect engagement of the contact button with a stationary contact 56a. `It will be evident from the foregoing and `from an examination of the drawings that the contact arms are adapted to be llexed simultaneously by corresponding actuator beads in response to operation of the armatures.

For the purpose of outlining the operation of the above described form of the invention, it is assumed that the relay shown in the drawings is assembled and that the parts are in the relative position shown in FIGS. 3 to 6. It is also assumed that magnetizing coils C are deenergized. Under these circumstances, both armatures are biased by their holding springs 52 so that their arms 42 are maintained away from pole pieces P, as illustrated in FIG. 3. In other words and having reference to FIG. 3, each armature A is pivoted in a clockwise direction about its shaft by its spring 52 to the extent allowed by corresponding stop linger 25.

When terminals 57 and 58 are connected to a suitable source of electric energy, the coils are energized and pole pieces P exert suicient attracting force on the armatures to pivot both armatures substantially simultaneously about the common axis of their shafts -against the action of springs 52. Thus, armature arms 42 are moved toward the pole pieces or in a counter-clockwise direction, as viewed in FIG. 3. This movement of the armatures and their arms causes actuator beads 48 to engage extensions 63 and flex movable contact arms 6l thereby breaking contact between contact buttons 62 and stationary contacts 55a and making contact between these buttons and stationary contacts 56a. When the magnetizing coils are again deenergized, the parts return to their original position.

The above described embodiment of the invention contemplates a relay construction wherein the armatures are rotatable simultaneously but independently. It is within the purview of this invention to actuate both armatures simultaneously and dependently. This may be accomplished by utilizing a single armature shaft which is rigidly secured to both armatures in the manner disclosed in said Patent No. 3,040,145.

From the foregoing, -it is believed that the objects, advantages, construction and operation of my present invention will be readily comprehended by persons skilled in the art, without further description. Although the invention has been herein shown and described in a simple and practicable form, it is recognized that certain parts thereof are representative of other parts which may be used in substantially the same manner to accomplish substantially the same results. Therefore, it is to be understood that the invention is not to be limited to the exact details described herein, but is to be accorded the full scope and protection of the appendeed claims.

I claim:

l. In a relay, a support frame, a pair of magnetizing coils carried by the frame, a pole piece in each coil, said pole pieces being independent of each other and including end parts that extend beyond the ends of the coils, a pair of armatures carried by the frame and rotatable about a common axis that is intermediate the poleI pieces, each armature including a pair of arms that extend to opposite sides of said axis and toward an end part of each pole piece, spring means normally and yieldingly imparting pivotal movement to each armature in one direction about said axis to swing the armature arms away from the pole pieces, a contact actuator affixed to each armature, a support plate connected to the frame, and a pair of stationary contacts and a pair of movable contacts secured to the support plate, the movable contacts being adapted to be moved along corresponding paths in a plane that is substantially parallel to said axis, each actuator being adapted, upon pivotal movement of its armature in a reverse direction against the action of the spring means, to engage and move a corresponding movable contact along its said path relative to a corresponding stationary contact.

2. In Ia relay, a support frame, a pair of magnetizing coils carried by the frame, a rectilinear pole piece in each coil, said pole pieces being substantially parallel and independent of each other and including end parts that extend beyond the ends of the coils, a pair of armatures carried by the frame and rotatable about a common axis that is intermediate and parallel to the pole pieces, the longitudinal axes of the pole pieces and said common axis lying in a first plane, each armature including a pair of arms that extend to opposite sides of said common axis and toward an end part of each pole piece, spring means normally and yieldingly imparting pivotal movement to each armature about said axis to swing the armature arms away from the pole pieces, a contact actuator aixed to each armature, a support plate connected to the frame, and a pair of stationary contacts and a pair of movable contacts secured to the support plate, the movable contacts being adapted to be moved along corresponding paths in a second plane that is substantially parallel to said rst plane, each actuator being adapted, upon pivotal movement of its armature in areverse direction against the laction of the spring means, to engage and move a corresponding movable contact along its said path relative to a corresponding stationary contact.

3. A relay according to claim 2 wherein the armatures are independently rotatable about said common axis.

4. A relay according to claim 2 wherein each actuator includes an element made of an electric insulating material, each element being disposed in a plane which is normal to said planes and which passes through the corresponding armature, and wherein each of said movable contacts comprises a flexible. resilient member, one end part of each member being anchored to the support plate, the other end part of each member being free and engageable by a corresponding actuator element.

5. In a relay, a support frame including a bottom wall and a pair of spaced upstanding side walls, a pair of magnetizing coils carried by the frame and positioned between the side walls, an independent pole p-iece in each coil and including end parts that extend through and beyond the side walls, a pair of armatures carried by the frame and rotatable about a common axis that is intermediate the pole pieces, each armature being positioned to the side of a corresponding side wall that is remote from the coils and including a pair of arms that extend to opposite sides of said axis and toward an end part of each pole piece, spring means normally and yieldingly imparting pivotal movement to each armature in one direction -about said axis to swing the armature arms away from the pole pieces, a contact actuator aiiixed to each armature, a support plate connected to the frame below and in spaced relation to the bottom wall, and a pair of stationary contacts and a pair of movable contacts secured to the support plate, the movable contacts being adapted to be moved along corersponding paths in a plane that is substantially parallel to said axis, each actuator being adapted, upon pivotal movement of its armature in a reverse direction against the action of the spring means, to engage and move a corresponding movable contact along its said path relative to a corresponding stationary contact.

6. In a relay, a support frame including a bottom wall and a pair of spaced upstanding side walls, a pair of magnetizing coils carried by the frame and positioned between the side walls, an independent rectilinear pole piece in each coil, said pole pieces being substantially parallel and including end parts that extend through and beyond the side walls, a pair of armatures carried by the frame and rotatable about a common axis that is intermediate and parallel to the pole pieces, the longitudinal axes of the pole pieces and said common axis lying in a iirst plane, each armature being positioned to a side of a corresponding side wall that is remote from the coils and including a pair of arms that extend to opposite sides of said axis and toward an end part of each pole piece, spring means normally and yieldingly imparting pivotal movement to each armature in one direction about said axis to swing the armature arms away from the pole pieces, a contact actuator affixed to each armature, a support plate connected to the frame below and in spaced relation to the bottom wall, and a pair of stationary contacts and a pair of movable contacts secured to the support plate, the movable contacts being adapted to be moved along corresponding paths in a second plane that is substantially parallel to said rst plane, each actuator being adapted, upon pivotal movement of its armature in a reverse direction against the action of the spring means, to engage and move a corresponding movable contact along its said path relative to a corresponding stationary contact.

7. A relay according to claim 6 wherein each actuator includes an element made of an electric insulating material, each element being disposed in a plane which is normal to said planes and which passes through the corresponding armature, and wherein each of said movable contacts comprises a flexible resilient member, one end part of each member being anchored to the support plate, the other end part of each member being free and engageable by a corresponding actuator element.

8. In a relay, a support frame including a bottom wall, a pair of spaced upstanding side walls and a plurality of legs depending from the bottom wall, a pair of magnetizing coils carried by the frame and positioned between the side walls, a pole piece in each coil and including end parts that extend through and beyond the side walls, a pair of armatures carried by the frame and rotatable about a common axis that is intermediate the pole pieces, each armature being positioned to the side of a corresponding side wall that is remote from the coils and including a pair of arms that extend to opposite sides of said axis and toward an end part of each pole piece, spring means normally and yieldingly imparting pivotal movement to each armature in one direction about said axis to swing the armature arms away from the pole pieces, a contact actuator affixed to each armature, a support plate secured to the frame legs below and in spaced relation to the bottom Wall, and a pair of stationary contacts and a pair of movable contacts carried by the frame plate and positioned in the spce between the frame plate and the bottom Wall, the movable contacts being adapted to be moved along corresponding paths in a plane that is substantially parallel to said axis, each actuator being adapted, upon pivotal movement of its armature in a reverse direction against the action of the spring means, to engage and move a corresponding movable contact along its said path relative to a corresponding stationary contact.

9. ln a relay, a support frame including a bottom wall, a pair of spaced upstanding side walls and a plurality of legs depending from the bottom wall, a pair of magnetizing coils carried by the frame and positioned between the side Walls, a rectilinear pole piece in each coil, said pole pieces being substantially parallel and including end parts that extend through and beyond the side walls, a pair of armatures carried by the frame and rotatable about a common `axis that is intermediate and parallel to the pole pieces, the longitudinal axes of the pole pieces and said common axis lying in a first plane, each armature being positioned to the side of a corresponding side wall that is remote from the coils and including a pair of arms that extend to opposite sides of said axis and toward an end part of each pole piece, spring means normally and yieldingly imparting pivotal movement to each armature in one direction about said axis to swing the armature arms away from the pole pieces, a contact actuator axed to each armature, a support plate secured to the frame legs below and in spaced relation to the bottom wall, and a pair of stationary contacts and a pair of movable contacts carried by the frame plate and positioned in the space between the frame plate and the bottom Wall, the movable contacts being adapted to be moved along corresponding g paths in a second plane that is substantially parallel to said rst plane, each actuator being adapted, upon pivotal movement of its armature in a reverse direction against the action of the spring means, to engage and move a corresponding movable contact along its said path relative to a corresponding stationary Contact.

l0. A relay according to claim 9 wherein each actuator includes an element made of an electric insulating material, each element being disposed in a plane which is normal to said planes and which passes through the corresponding armature, and wherein each of said movable contacts comprises a ilexible resilient member, one end part of each member being anchored to the support plate, the other end part of each member 'being free and engageable by a corresponding actuator element.

1l. A relay according to claim 9 wherein the support frame is one-piece in construction and the armatures are independently rotatable about said common axis.

12. A relay according to claim 9 wherein the support frame is one-piece in construction and the armatures are directly connected and rotatable in unison about said common axis.

References Cited in the le of this patent UNITED STATES PATENTS 1,267,483 Walley May 28, 1918 1,462,585 Soreng July 24, 1923 2,824,189 Zimmer Feb. 18, 1958 2,875,293 Adams Feb. 24, 1959 2,923,794 Keeran Feb. 2, 1960 2,931,872 Sprando Apr. 5, 1960 2,946,873 Distin July 26, 1960 2,951,134 LaZich -e Aug. 30, 1960 

